Filter Element

ABSTRACT

The invention relates to a filter element comprising a filter material ( 10 ) which comprises individual filter folds ( 12 ) which are folded in a star-like manner, at least one fluid-permeable support element ( 26 ) which extends at least partially in the space between two adjacent filter folds ( 12 ) and/or on the inner peripheral side and/or external peripheral side of the filter folds ( 12 ). The invention is characterised in that the respective support element ( 26 ) is provided with filter-active substances or is made of said filter-active substances. A certain type of filter auxillary agent can be obtained which is used to reduce influences of fluid components which reduce the service life, in the form of specific ageing products or in the form of other agents which damage the fluid.

The invention relates to a filter element with a filter material which has individual filter folds which are folded in a star shape, at least one fluid-permeable support means extending at least partially into the space of two adjacent filter folds and/or on the inner peripheral side and/or the outer peripheral side to the filter folds.

Filter elements such as these are readily available on the market in a plurality of embodiments. These filter elements are used when inserted in the filter housing to clean the supplied dirty fluid, for example in the form of a hydraulic medium, by using the filter material of the filter element, and to return the fluid which has been cleaned in this way from the filter housing to the fluid circuit, in particular the hydraulic circuit. If after a plurality of filter cycles the filter material is clogged with dirt such that it is used up, the filter element is removed from the housing and is replaced by a new one. To increase the filtering surface, modern filter elements have a filter mat web which is folded in a star shape and which surrounds an inner or outer support tube in a concentric circle, against which the filter material with its filter folds folded up in a star shape can be supported. Especially when flow takes place through the filter element from the outside to the inside, can the filter folds be supported on the indicated support tube during filtration in this way. In this respect there is also the possibility of reversing the filtration direction, that is, from the inside to the outside, and furthermore backflushing processes with already cleaned fluid are also conceivable in order to clean the filter material clogged by dirt. The filter material itself has a multilayer mat structure, the layer structure being dependent on the filtration task to be performed. But generally layer structures are used here with clean filtering and draining layers, composed of native fibers, plastic fibers, such as meltblown fibers, glass fibers, and the like. In order to ensure a fixed association of layers against one another, provision can moreover be made such that that the two cover layers of the filter material consist of a fine-mesh wire fabric and in this way seek to prevent washout of the fiber material.

The disadvantage of filter materials which have been folded in a star shape in this way is that the individual filter folds can be deformed during filtration and come to rest on one another, forming a block; this reduces the surface which is effective for filtration and consequently degrades filter performance. These faults occur especially in fluids with high viscosity, as however generally occur for example in a cold start of a fluid system or hydraulic system. Blockage of the folds causes a degradation of drainage; this ultimately leads to increased pressure losses at a reduced dirt holding capacity and a reduced service life for the filter element.

In order to help avoid unwanted deformation of the folds and formation of fold blocks, the prior art (WO 01/85301 A1) has already suggested surrounding the concentrically arranged filter material with its filter folds on the outer peripheral side with a support means which is supported as a type of hollow cylinder with its outer periphery on the inner periphery of the outer housing part of the filter element, and on the inner peripheral side forms individual projections which engage the spaces between adjacent filter folds and in this way prevent them from coming to rest on one another in an undesirable manner or even from being folded over. Since in the known solution the fluid-permeable support means is formed from a type of porous sponge (available under the trademark “SIF” from Foamex International Inc., 10000 Columbia Avenue, Linwood, Pa. 19061), it has high inherent elasticity so that with a certain pretensioning the adjacent filter folds are kept at a distance from each other and can engage the depressions of the otherwise cylindrical foam support means.

With the known solution, very good supporting effects can be achieved and failure of the filter element, even at higher fluid viscosities, as occur in cold starts, is precluded in this way. In addition to increasing the operating reliability, the known solution can also be economically implemented.

But it has been found that the known solution is still susceptible to blockage; this is caused by ageing products in the fluid which can lead to the entire filter element becoming choked and unusable. Thus, among other things, the types of oil used in wind power plants are characterized by a high content of additives in order to be able to form very good tribologic properties, with the disadvantage that in the aged state of the oil they occur as ageing products or oil residues which are not oil-soluble, and which then cement the surface of the filter material so that in this respect the filter element can only make available a part of the actual dirt holding capacity in filtration. This in turn leads to increased pressure losses and to reduced service life of the optimized filter element with support means.

On the basis of this prior art therefore the object of the invention is to further improve the known solutions with support means while retaining their advantages, such that possible blockage of the element by ageing products (choking) is prevented. This object is achieved by a filter element with the features of claim 1 in its entirety.

In that, as specified in the characterizing part of claim 1, the respective support means is provided with filter-active substances or is itself composed of these filter-active substances, a kind of filtering aid can be obtained which is used to reduce the effect of fluid components which reduces the service life, whether in the form of specific ageing products, or in the form of other media which damage the fluid, such as acid portions or the like. Depending on the selected filter-active substances, microorganisms can be kept away from the fluid flow. Preferably the filter-active substances used are those which can offer a high specific surface in order in this way to obtain good bonding of the substances and particles which damage the fluid.

The indicated filter-active substances are used as a type of particle scavenger and can prevent migration of the damaging substances to the clean side of the filter element for example in bonding with a foam-like body as the support means which keeps the filter folds in position. Thus for example by settling of the oil ageing products on the particle scavengers which act in this way as sludge catchers, the filter material of the filter element can be relieved such that it can again perform its actual task of separating the solids from the fluids. Use of the filter-active substances as particle scavengers on the clean side of the filter is less to be recommended due to lower efficiency; in coaxial solutions in which however one filter element is located concentrically to the other filter element in it or adjacent to it, an intermediate layer of filter-active substances can be advisable which then must lie on the clean side of the filter element which precedes it in the fluid direction. In filter elements, however, through which flow takes place from the inside to the outside preferably for filtration, the support means with the filter-active substances then should be located on the inside of the filter element, that is, in turn in the inflow direction in front of the actual filter material.

Preferably the respective support means for the purpose of doping is provided with filter-active substances; but it is also possible for the filter-active substances themselves to form the support means as a whole or for the most part, for example when in the form of charging with pourable filter-active substance the individual distances between the filter folds are filled, and here preferably charging must take place such that on the dirty side of the filter element the filter folds experience support.

In one preferred embodiment of the filter element according to the invention, the support means consists of a porous, especially sponge-like basic structure, in the pores of which to some extent the filter-active substances, such as bentonite, perlite, activated charcoal, kieselguhr, are enclosed and/or it is provided that the basic structure is composed of dual-component fibers. Depending on the filter-active substances used as the filtering aids, deep-bed filter or even membrane filter properties can be achieved in this way.

Other advantageous embodiments are the subject matter of the other dependent claims.

The filter element according to the invention will be detailed below using one embodiment as shown in the drawings. The figures are schematic and not to scale.

FIG. 1 shows as an exploded drawing one embodiment of the filter element according to the invention as a whole;

FIG. 2 shows a cross section through the filter element as shown in FIG. 1 in the assembled state along one center plane.

The filter element shown in FIG. 1 has filter material 10 which is folded in a star shape as a pleated filter mat and accordingly has individual filter folds 12. The respective filter material 10 which has been folded in this way forms a type of hollow cylinder and especially the mat structure for the filter material 10 has multiple layers (not shown) with supporting drainage layers located on the outside layer, and filtering main filter layers located in between, and the interconnected layers can be supported both to the outside and also to the inside by wire cloth. This filter material structure of native fibers, plastic fibers such as meltblown fibers or the like, is conventional so that it will not be detailed here. To the inside the filter material 10 is supported by an inner support tube 14 which is provided with perforation sites 16. To the outside, that is, on the outer peripheral side, the filter material 10 is surrounded by an outer support tube 18 with perforation sites 20. This outer support tube 18 can also be made as a thin-walled, outer housing jacket, for example in the form of a fluid permeable metal screen structure (not shown). Viewed in the direction of looking at FIG. 1 to the top and bottom, the filter material 10 is bordered by two end caps 22 which in the center have recesses 24 for possible fluid passage and between the raised edges of the end caps 22 the two support tubes 14, 18 and the filter material 10 can be inserted adhesively on the end side so that in this way a filter element made in one piece as a replacement part for a filter housing which is not detailed is formed which can be used in a fluid system, especially a hydraulic system.

Furthermore, FIG. 1 shows a fluid-permeable, cylindrical support means 26 which is located between the inner peripheral side 28 of the element housing 18 and the outer periphery along the outside of the filter folds 12. This arrangement in the assembled state of the filter element as shown in FIG. 1 is reproduced in FIG. 2 and in the illustrated embodiment the support means 26 is formed from a porous, especially spongy base structure as the base matrix, due to the inherent elasticity of the base structure the outer filter folds 12 engaging the foam material and the convexly protruding projections 30 of the support means 26 engaging the existing spaces between the adjacent filter folds 12 of the filter material 10. As a result of these projections 30, the filter folds 12 which are supported on the inner peripheral side on the inner support tube 12 are held in position and even for very highly viscous, waxy fluid, as a result of the support means it cannot happen that the filter folds 12 are moved in their location such that they bend or stick to one another to form blocks; this otherwise leads to a reduction of the dirt holding capacity with the above described disadvantage.

In spite of these measures which are disclosed in the prior art (WO 01/85301 A1), the filter element can become unusable, in particular the filter can be blocked, if for example ageing products as a type of choking settle between the filter folds 12 on the filter material 10. In particular, in wind power plants hydraulic media and types of oil are used which due to the high stress on them in this field have a high content of additives. In the aged state of the fluid medium then oil-insoluble ageing products or oil residues occur which cement the surface of the filter element so that the filter element can again reach only a fraction of its actual dirt holding capacity at all; this reduces the service life of the filter element and as a result of blockage a correspondingly high pressure loss occurs with the consequence that the filter elements must be changed at very short maintenance intervals in order not to endanger the operation of the overall hydraulic system. Regardless or in addition, of course the fluid can be further burdened, for example can have highly acid-containing components, can contain special abrasive media or entrain even microorganisms which can damage highly sensitive mechanical parts and the quality of the fluid.

Because the respective support means 26 is provided with filter-active substances or even is built up from these filter-active substances, in this way “particle scavengers” which are enclosed in the region of the filter material 10 of the filter element can be created which, depending on the specification, can remove fluid- or component-damaging components from the fluid flow. Thus, for example it is possible to sort out the indicated ageing products which can lead to choking of the filter element by way of the indicated filter-active substances as particle scavengers, and even before they can reach the sensitive filter material 10, so that in this way the oil-insoluble ageing products or oil residues can be retained in the manner of prefiltration or pretreatment. To achieve this effect, the support means 26 with the working filter-active substances should be located on the dirty side and as a preferred option a fluid flow space 32 should remain between the exit wall of the support means 26 and the entry wall for the respective filter fold 12 in order to achieve undisturbed flow while avoiding cavitation.

If the support means 26 consists of a porous, especially sponge-like base structure as the matrix, at least in part filter-active substances, such as bentonite, perlite, activated charcoal, kieselguhr or the like can be enclosed in its pores, its having proven to be especially advantageous to build up the base structure itself from so-called dual-component fibers. In this way, for the purpose of doping there is the possibility of acting on the basic structure of the support means 26 and the indicated filter-active substances form a type of filtering aid, in this way there being body geometries with a high specific surface; this enables a particle retention capacity to an increased degree. By corresponding mixtures of filter-active substances then not only potential oil-insoluble ageing products, but also acid portions of fluids or microorganisms could be retained via the activated charcoal portions of the filter aid mixture and could be removed from the fluid flow.

To the extent the support means 26 is built up from so-called dual-component fiber systems, preferably a polyolefin fiber core with a high melting point (for example a polypropylene core) is selected which is concentrically surrounded by a fiber jacket of polyolefin material with a low melting point (for example in the form of a polyethylene jacket). This structure has the advantage that in the production of the matrix under temperature the outer jackets of the fibers melt quickly and are joined to one another without the fiber cores being adversely affected in their stability, so that in this way a fine-mesh matrix structure is obtained which is intended for doping with the filter-active substances. For certain retention tasks it can then also be sufficient to form only one base structure as the support means 26 from dual-component fibers without doping with filtering aids. In order to form the support means 26 for purposes of a deep-bed filtration solution, it has the form of a matrix of self-binding plastic and/or natural fibers (cellulose) which are at least partially fibrillated, a finely fibrillated fiber substance, especially ground cellulose, being introduced into the support means 26 itself and for this purpose the support skeleton, and the inert particles in the form of agglomerate particles with a defined size between 0.5 to 100 μm, especially in the form of a finely dispersed kieselguhr, can improve filter properties.

In the solution shown in FIG. 2, the support means 26 surrounds the outer sides of the filter folds 12. For the purposes of further optimization of the solution according to the invention, it would now be possible to introduce another filter-active substance into the fluid flow space 32, for example in the form of activated charcoal which can be easily fed into the fluid flow space 32. In this way, with the spongy base structure located on the outer peripheral side, oil ageing residues could be retained and by means of activated charcoal microorganisms or the like could be filtered out of the fluid flow. Depending on the desired specification, there could also conceivably be mixtures of bentonite, perlites, activated charcoal and kieselguhr which could fill the intermediate spaces as pourable media between the filter folds 12 also on the clean side of the filter. It would also be conceivable in a concentric arrangement to place these filter-active substances as a hollow cylinder in intermediate spaces, which are not detailed, between the inner support tube 14 and the inner filter folds 12 or even to replace the inner support tube 14 with this hollow cylinder. The support means 26 shown in FIGS. 1 and 2 in the form of a base material can also be completely omitted and the filter-active substances are then, as shown, moved by way of pouring into the spaces between the filter folds 12, especially on their dirty side. This can result in solutions which are especially geometrically small, since then the outer support tube 18 or housing part can be supported with its perforation sites 20 directly on the outer periphery with the filter folds 12 of the filter material 10. 

1. Filter element with a filter material (10) which has individual filter folds (12) which are folded in a star shape, at least one fluid-permeable support means (26) extending at least partially into the space of two adjacent filter folds (12) and/or on the inner peripheral side and/or the outer peripheral side to the filter folds (12), characterized in that the respective support means (26) is provided with filter-active substances or is itself built up from these filter-active substances.
 2. The filter element according to claim 1, wherein the support means (26) consists of a porous, especially sponge-like basic structure, in the pores of which at least to some extent the filter-active substances, such as bentonite, perlite, activated charcoal, kieselguhr, are enclosed and/or wherein the base structure is composed of dual-component fibers and/or from a poured bed of filter-active substances, such as activated charcoal.
 3. The filter element according to claim 2, wherein the individual filter folds (12) of the filter material (10) are encompassed by the base structure on the inner and/or outer peripheral side and/or wherein the base structure over a definable radial distance engages the spaces between the individual filter folds (12) by way of projections (30).
 4. The filter element according to claim 2, wherein the base structure in the manner of a support tube surrounds the filter material (10) on the inner and/or outer peripheral side.
 5. The filter element according to claim 2, wherein the filter folds (12) of the filter material (10) form a hollow cylindrical, especially a multilayer part of a mat web, which is supported on the inner peripheral side on a separate support tube (14) and to the outside on a hollow cylindrical, perforated housing part (18) and wherein between the housing part (18) and the outer peripheral side region of the part of the mat web the hollow cylindrical base structure is located as an independent compact component (support means 26).
 6. The filter element according to claim 1, wherein the filter material (10) with the respective base structure extends between the two end caps (22) as part of the filter element.
 7. The filter element according to claim 2, wherein the support means (26) in the form of a matrix consists of self-binding plastic fibers and/or natural fibers which are at least partially fibrillated.
 8. The filter element according to claim 7, wherein a finely fibrillated fiber, especially ground cellulose, and/or inert particles in the form of agglomerate particles with a defined size between 0.5 to 100 μm in the form of finely dispersed kieselguhr are introduced into the matrix.
 9. The filter element according to claim 2, wherein the dual-component fibers have a core of polypropylene and a jacket of polyethylene. 